Laminate wafers

ABSTRACT

A laminate optical article including a first outer layer; a second outer layer; and an inner layer positioned between said first and second outer layers, the inner layer providing a desirable optical property to the laminate optical article.

The present invention relates to the manufacture of plastic opticalarticles such as sunglass lenses, ophthalmic lenses and the like. Inparticular, the present invention relates to the manufacture of laminateoptical articles.

It is known in the prior art that in the manufacture of optical articlesit is often desirable to provide additional properties to the articles,for example polarisation, UV inhibition, photochromism, electrochromism,or colouration of lenses.

Such properties are normally provided by the addition of a coating orsurface treatment to the finished lens. However, such treatments aredifficult and expensive to apply, and may be removed from the opticalsurface by scratching, wearing or the like.

Further, for example, it is known in the prior art to incorporatephotochromic dyes into a plastic lens via surface imbibation techniques.See for example U.S. Pat. No. 5,130,353, or U.S. Pat. No. 5,185,390,which describe the inclusion of photochromic dyes into the subsurfaceregion of a plastic lens by first positioning a polymeric or othercarrier or photochromic dye physically against the surface of the lensand then using heat to cause the dyes to diffuse into the lens. Suchtechniques are both difficult and expensive, and require careful controlof the depth of absorption in order to achieve a constant colour for thelens.

Further, it has been proposed in the prior art, e.g. in Japanese Patent1259591 (1984) and Japanese Patent application 5181016 (1993), tointroduce a film having desirable properties by placing a foil into amould and cast polymerising a lens. Numerous problems have beenassociated with this art, however, including the formation of bubbles,haze and visible stress birefringence in the finished lens.

It would therefore be a significant advance in the art to provide aprocess for improving optical properties which was easy to handle andproduced a product of enhanced durability.

It is accordingly an object of the present invention to overcome, or atleast alleviate, one or more of the difficulties or deficiencies relatedto the prior art.

Accordingly, in a first aspect of the present invention there isprovided a laminate optical article including

a first outer layer;

a second outer layer; and

an inner layer positioned between said first and second outer layers,the inner layer providing a desirable optical property to the laminateoptical article.

The laminate optical article may be characterised by improved durabilityand ease of handling. The laminate structure provides a product thecomponents of which are of relatively simple geometry and are thus easyto manufacture.

The first outer layer may form a front or back wafer of a laminateoptical lens. The first outer layer may include an optical surface andan interface or mating surface. The optical surface may have differentoptical powers along different meridians. Alternatively the opticalsurface may include an aspheric bi-focal, tri-focal or progressivemulti-focal region or regions.

The first outer layer may be formed from any suitable material. Amineral glass or optical polymeric material may be used. The polymericmaterial may be of any suitable type. The polymeric material may includea thermoplastic or thermoset material. A material of the polycarbonatetype, may be used. The laminate optical article is particularly suitablein polycarbonate applications. The laminate optical article may reduceor eliminate difficulties associated with the high stress co-efficientof birefringence associated with polycarbonates. The consequence of thisis that when polycarbonate is moulded utilising conventional processes,flow lines and areas of stress are highly visible, for example whenviewed through a polarising film.

Alternatively, the polymeric material may be of the diallyl glycolcarbonate type, for example the product sold under the trade designationCR-39 (CR-39 is a Registered Trade Mark of PPG Industries, Inc.).

The polymeric material may be formed from cross-linkable polymericcasting compositions, for example as described in applicants U.S. Pat.No. 4,912,155, U.S. patent application Ser. No. 07/781,392, AustralianPatent Applications 50581/93 and 50582/93, and European PatentSpecification 453159A2, the entire disclosures of which are incorporatedherein by reference.

Such cross-linkable polymeric casting compositions may include adiacrylate or dimethacrylate monomer (such as polyoxyalkylene glycoldiacrylate or dimethacrylate or a bisphenol fluorene diacrylate ordimethacrylate) and a polymerisable comonomer, e.g. methacrylates,acrylates, vinyls, vinyl ethers, allyls, aromatic olefins, ethers,polythiols and the like.

For example, in Australian Patent Application 81216/87, the entiredisclosure of which is incorporated herein by reference, applicantdescribes a cross-linkable coating composition including at leastpolyoxyalkylene glycol diacrylate or dimethacrylate and at least onepoly functional unsaturated cross-linking agent.

Further, in Australian Patent Application 75160/91, the entiredisclosure of which is incorporated herein by reference, applicantdescribes a polyoxyalkylene glycol diacrylate or dimethacrylate; amonomer including a recurring unit derived from at least oneradical-polymerisabie bisphenol monomer capable of forming a homopolymerhaving a high refractive index of more than 1.55; and a urethane monomerhaving 2 to 6 terminal groups selected from a group comprising acrylicand methacrylic groups.

Such polymeric formulations are UV cured or cured by a combination of UVand thermal treatment. The range of optical lenses sold under the tradedesignations “Spectralite” by Applicants have been found to be suitable.

The polymeric material may include a photochromic dye which may, forexample, be added to the monomer formulation used to produce thepolymeric material.

The second outer layer of the laminate optical article may be of anysuitable type. The second outer layer may form a protective coating forthe inner layer described above. The protective coating may include oneor more of the groups consisting of an abrasion resistant component, awater resistant component and an antistatic component. A peel-offprotective layer may be used. The protective coating may be formed of apolymeric material. A vinyl polymer material may be used. A vinylchloride/vinyl acetate copolymer is preferred. The protective coatingmay further include conventional components including plasticisers,anti-static agents and the like.

The laminate optical article so formed may be packaged for laterlamination to, for example, a front or back lens wafer. A water-barrierresistant package may be used, Such packages may control relativehumidity such that the stability of curvature of the lens wafers isretained. A package of the type described in U.S. Pat. No. 5,323,192 toapplicants, the entire disclosure of which is incorporated herein byreference, may be used.

Alternatively, the second outer layer may form a complementary back orfront wafer of a laminate optical lens. The second optical layer mayform a complementary back or front wafer to the first outer layer. Thesecond outer layer may be formed in a complementary though reversemanner to the first outer layer.

Accordingly, in a preferred aspect of the present invention there isprovided a laminate optical article including

a front lens wafer formed from a optical polymeric material;

a second complementary back lens wafer formed from a optical polymericmaterial; and

an inner layer positioned between said front and back wafer and having ashape complementary to a surface complementary to a surface of the frontand/or back wafer, the inner layer providing a desirable opticalproperty to the laminate optical article.

If desired, there may be a distribution of distance power and cylinderbetween the front and back lens wafers. Alternatively, the back lenswafer may be relatively thick, the laminate optical article forming asemi-finished lens.

The inner layer may be of any suitable type. The inner layer may includea polymeric film having desirable optical properties. The inner layermay include a foil, that is a film having structural integrity.

The inner layer may be of any suitable size and shape. The inner layermay be formed to have a shape complementary to a surface of the firstouter layer and/or second outer layer. The inner layer may be moulded,cast, blown or otherwise shaped to have a complementary surface to thefirst outer layer and/or second outer layer.

The inner layer may be trimmed in situ or more preferably may be pre-cutto size. The edge of the inner layer may include a return flange to aidin dimensional stability and handling.

The inner layer may be formed to substantially correspond to the shapeof an interface or mating surface of the first outer layer and/or secondouter layer. Where the interface or mating surface is a curved surface,the inner layer may have a curvature which substantially corresponds tothe curvature of the inner surface of the first and/or second outerlayer. A typical curvature required would be of the order ofapproximately 4 to 8 dioptre.

It will be understood that in this preferred form since the interfacesurface(s) of the front lens wafer and/or second complementary back lenswafer can be kept relatively simple, the formation of the inner layer isalso relatively simple and can be controlled within very closetolerances. This may reduce or prevent formation of bubbles and otheroptical distortions.

The desirable optical properties may be inherent in the nature of thepolymeric film,. For example, a vinyl alcohol polymer may be used. Ahydrolysed polyvinyl acetate (polyvinyl alcohol) may be used. Thepolyvinyl alcohol may be highly oriented to produce a polarising film orfoil. The polyvinyl alcohol may be iodine impregnated. A polyvinylacetate or polyvinyl butyrate polymer may be included. Such a polymermay include an active light polarising films. The polyvinyl alcohol filmor foil may be provided, in a preferred form, in a cellulose acetatebutyrate or like laminate.

Alternatively, the inner layer may include a polymeric film or foilhaving incorporated therein an optically active component.

The polymeric film or fail may be of any suitable optically transparentor transmissible material. The polymeric film may be selected fromoptically transparent acrylics, vinyls, allyls, esters and the like.

Where the inner layer exhibits UV absorbing characteristics, for examplewith a polarising film or foil, it is preferred to select a materialwhich does not exhibit a sharp UV cut off. Such a UV out off may presentdifficulties where a UV curable adhesive is used in the laminationprocess. For example UV cure may be conducted around 365 nm so lowtransmission in this region may result in poor laminate adhesion.

Alternatively where a sharp UV cut off is required, for example insunglass applications, a visible light curable adhesive may be used.

Similarly, the laminate optical, article may be formed from a polymericmaterial exhibiting a UV cutoff. Such polymeric materials are disclosedin International Patent Application PCT/AU96/00705 “Light TransmissibleArticle with Reduced Ultraviolet Transmission” to applicants, the entiredisclosure of which is incorporated herein by reference.

Where a photochromic film is required, the polymeric film may be formedfrom cross-linkable polymeric casting compositions, such as a blend ofpolyoxyalkylene glycol diacrylate or dimethacrylate together withradical-polymerisable bisphenol monomer and a urethane monomer having 2to 6 terminal groups selected from a group comprising acrylic ormethacrylic groups. A preferred composition is a blend ofpolyoxyalkylene glycol dimethacrylate with urethane methacrylate.

The optically active component may be selected from one or more of thegroup consisting of light polarising materials, ultra-violet inhibitors,photochromic materials, electrochromic materials and other pigments ordyes.

The pigment(s) or dye(s) including photochromic dye(s) may be selectedfrom one or more of the group consisting of anthraquinones,phthalocyanines, spiro-oxazines, chromenes, pyrans includingspiro-pyrans and fulgides. The photochromic dye(s) may be incorporatedinto the monomer formulation used to produce the polymer of the innerlayer.

Examples of preferred photochromic dyes may be selected from one or moreof the group consisting of

1,3-dihydrospiro[2H-anthra[2,3-d]imidazole-2,1′-cyclohexane]-5,10-dione

1,3-dihydrospiro[2H-anthra[2,3-d]imidazole-2,1′-cyclohexane]-6,11-dione

1,3-dihydro-4-(phenylthio)spiro[2H-anthra′1,2-diimidazole-2,1′-cyclohexane]-6,11-dione

1,3-dihydrospiro[2-H-anthra[1,2-d]imidazole-2,1′-cycloheptane]-6,11-dione

1,3,3-trimethylspiro′indole-2,3′-[3H]naphtho[2,1-b]-1,4-oxazine]

2-methyl-3,3′-spiro-bi-[3H-naphtho[2,1-b]pyran](2-Me)

2-phenyl-3-methyl-7-methoxy-8′-nitrospiro[4H-1-benzopyran-4,3′-[3H]-naphtho][2,1-b]pyran

Spiro[2H-1-benzopyran-2,9′-xanthene]

8-methoxy-1′,3′-dimethylspiro(2H-1-benzopyran-2,2′-(1H)-quinoline

2,2′-Spiro-bi-[2H-1-benzopyran]

5′-amino-1′,3′,3′-trimethylspiro[2H-1-benzopyran-2,2′-indoline

Ethyl-β-methyl-β-(3′,3′-dimethyl-6-nitrospiro(2H-1-benzopyran-2,2′-indolin-1′-yl)-propenoate

(1,3-propanediyl)bis[3′,3′-dimethyl-6-nitrospiro[2H-1-benzopyran-2,2′-indoline]

3,3′-dimethyl-6-nitrospiro[2H-1-benzopyrao-2,2′-benzoxazoline]

6′-methylthio-3,3′-dimethyl-8-methoxy-6-nitrospiro[2H-1-benzopyran-2,2′-benzothiozoline]

(1,2-ethanediyl)bis[8-methoxy-3-methyl-6-nitrospiro[2H-1-benzopyran-2,2′-benzothiozoline]

N-N′-bis(3,3′-dimethyl-6-nitrospiro[2H-1-benzopyran-2,2′(3′H)-benzothioazol-6′-yl)decanediamide

-α-(2,5-dimethyl-3-furyl)thylidene(Z)-ethylidenesuccinic anhydride;α-(2,5-dimethyl-3-furyl)-α′, δ-dimethylfulgide

2,5-diphenyl-4-(2′-chlorophenyl)imidazole

[(2′,4′-dinitrophenyl)methyl]-1H-benzimidazole

N-N-diethyl-2-phenyl-2H-phenanthro[9, 10-d]imidazol-2-amine

2-Nitro-3-aminofluorene

2-amino-4-(2′-furanyl)-6H-1,3-thiazine-6-thione

3,3-di(4-methoxyphenyl)-6-morpholino-3H-naphtho[2,1-b]pyran (ReversacolCorn Yellow)

3,3-di(4-methoxyphenyl)-3H-naphtho[2,1-b]pyran (Reversacol Tangerine)

2,2-di(4-methoxyphenyl)-5,6-dimethyl-2H-naphtho[2,1-b]pyran (ReversacolBerry Red)

1,3-dihydro-3,3-dimethyl-1-isobutyl-spiro[2H-indole-2,3′-[3H]naphth[2,1-b][1,4]oxazine](Reversacol Oxford Blue)

1,3-dihydro-3,3-trimethyl-1-neopentyl-6′-(4-diethylaminophenyl)spiro[2H-indole-2,3′-[3H]naphth[2,1,b]oxazine](Reversacol Sea Green)

1,3-dihydro-3,3-dimethyl-1-isobutyl-6′-(4-diethylaminophenyl)spiro[2H-indole-2,3′-[3H]naphth[2,1-b][1,4]oxazine](Reversacol Aqua Green)

1,3-dihydro-3,3-dimethyl-1isobutyl-6′-indolinospiro[2H-indole-2,3′-[3H]naphth[2,1-b][1,4]oxazine] (Reversacol FlatPurple)

1,3-dihydro-3,3-dimethyl-1-(2-phenylpropyl)-6′-indolinospiro[2H-indole-2,3′-[3H]naphth[2,1-b][1,4]oxazine] (Reversacol StormPurple)

1,3-dihydro-3,3-dimethyl-1 isobutyl-6′-piperidinospiro[2H-indole-2,3′-[3H]naphth[2,1-b][1,4]oxazine] (Reversacol PlumRed)

1,3-dihydro-5-chloro-3,3-dimethyl-1isobutyl-6′-piperidinospiro[2H-indole-2,3′-[3H]naphth[2,1-b][1,4]oxazine] (Reversacol Claret)

In a preferred aspect, one or more of the layers of the laminate opticallayer may be subjected to a surface treatment to improve bondabilityand/or compatibility. The surface treatment may be selected from one ormore of the group consisting of plasma discharge, corona discharge, glowdischarge, radiation, UV radiation, flame treatment and laser,preferably excimer laser treatment.

Preferably the inner layer is subjected to a plasma or corona dischargetreatment.

In a further preferred aspect the optical laminate article may include aplurality of inner layers, each providing one or more desirable opticalproperties to the article. A combination of a photochromic inner layerand a polarising inner layer is particularly preferred.

The laminate optical article may further include standard additionalcoatings to the front or back surface.

The optical, preferably front lens, surface may include ananti-reflective (AR) coating, for example of the type described in U.S.Pat. No.5,704,692 to applicants, the entire disclosure of which isincorporated herein by reference. This is particularly suitable wherethe inner layer is a polarising film or foil. In conventionalprocessing, when lens are AR coated they go through a stringent thermalregime, and this can damage the polarising foil. As the AR coating maybe applied to a front and/or back lens wafer prior to assembly of thelaminate article, thermal damage to the polarising film is simplyavoided.

The optical, preferably front lens surface may include an abrasionresistant coating. e.g. of the type described in U.S. Pat. No. 4,954,591to applicants, the entire disclosure of which, is incorporated herein byreference.

In a further preferred aspect of the present invention there is provideda series of laminate optical articles each member of the seriesincluding

a back lens wafer formed from a optical polymeric material;

an outer layer forming a protective coating; and

an inner layer positioned between said back lens wafer and outerprotective layer, the inner layer providing a desirable optical propertyand shaped to have a curvature substantially corresponding to theinterface surface of the back lens wafer.

Desirably successive members of the series may have suitable sphere andcylinder power to enable a member of the series to be used incombination with any design and power of front lens wafer to produce afinished lens within the normal tolerances for such lenses.

It is simply necessary to remove the protective coating just prior toattachment to the front lens wafer to provide a pristine and stablesurface for lamination.

Alternatively, in a further preferred aspect, there is provided alaminate optical article including

a front lens wafer formed from a optical polymeric material;

an outer layer forming a protective coating; and

an inner layer positioned between said back lens wafer and outerprotective layer, the inner layer providing a desirable optical propertyand shaped to have a curvature substantially corresponding to theinterface surface of the front lens wafer.

The laminate optical article may further include a back lens waferselected from a series of back lens wafers as described above.

Such back wafer series are described in U.S. Pat. No. 5,187,505, toapplicants, the entire disclosure of which is incorporated herein byreference.

The front and back lens wafer may further include one or more additionsconventionally used in casting compositions such as inhibitors, dyesincluding electrochromic and photochromic dyes, e.g. as described above,polarising agents, UV stabilisers and materials capable of modifyingrefractive index. Such additives may include:

UV Absorbers including

Ciba Geigy Tinuvin P -2(2′-hydroxy-5′methyl phenyl) benzotriazole

Cyanamid Cyasorb UV 531-2-hydroxy-4-n-octoxybenzo-phenone

Cyanamid Cyasorb UV5411-2(2-hydroxy-5-t-octylphenyl)-benzotriazole

Cyanamid UV 2098-2 hydroxy-4-(2-acryloyloxyethoxy) benzophenone

National Starch and Chemicals Permasorb MA -2 hydroxy-4-(2hydroxy-3-methacryloxy)propoxy benzophenone

Cyanamid UV24-2,2′-dihydroxy-4-methoxybenzophenone

BASF UVINUL 400-2,4dihydroxy-benzophenone

BASF UVINUL D-49-2,2′-dihydroxy-4,4′dimethoxy-benzophenone

BASF UVINUL D-50-2,2′,4,4′tetrahydroxy benzophenone

BASF UVINUL D-35-ethyl-2-cyano-3,3-diphenyl acrylate

BASF UVINUL N-539-2-ethexyl-2-cyano-3,3-diphenyl acrylate

Ciba Geigy Tinuvin 213

Hindered amine light stabilisers (HALS), including

Ciba Geigy Tinuvin 765/292- bis (1,2,2,6,6-pentamethyl-4-piperidyl)sebacate

Ciba Geigy 770- bis (2,2,6,6-tetramethyl-4-piperidinyl) sebacate

Antioxidants including

Ciba Geigy Irganox 245- triethylene glycol-bis-3-(3-tertbutyl-4-hydroxy-5-methyl phenyl)propionate

Irganox1010-2,2-bis[[3-[3,4-bis(1,1-dimethylethyl)-4-hydroxyphenyl]-1-oxopropoxy]methyl]-1,3-propanediyl3,5-bis(1,1-dimethyl ethyl)-4-hydroxy benzene propanoate

Irganox 1076- octadecyl 3-(3′,5′-di-tert-butyl(-4′- hydroxyphenyl)propionate

Anticolouring agents including

9, 10 dihydro-9-oxa-10-phosphaphenanthrene-1-oxide

Other monomeric additives may be present in, e.g. amounts up to 10% byweight as viscosity modifiers, and include monomers such as methacrylicacid, vinyl silanes, and other functional monomers. Other monomericadditives may be included to improve processing and/or materialproperties, these include:

methacrylic acid, maleic anhydride, acrylic acid

adhesion promoters/modifiers such as Sartomer 9008, Sartomer 9013,Sartomer 9015 etc.

dye-enhancing, pH-adjusting monomers like Alcolac SIPOMER 2MIM

a charge-reducing cationic monomer to render the material moreantistatic, example Sipomer Q5-80 or Q9-75

The laminate optical article according to the present invention may beformed utilising any suitable techniques. Desirably, the laminateoptical articles may be formed utilising a light curable adhesive,preferably a visible light or ultra-violet (UV) curable adhesive.

Accordingly, in a further preferred aspect there is provided a methodfor preparing a laminate optical article including

providing

a first outer layer formed from an optical polymeric material;

an inner layer formed from a polymeric film and capable of providing adesirable optical property to the final product; and

a light curable adhesive;

contacting at least a portion of a surface of the first outer layer withthe light curable adhesive;

contacting a surface of the inner layer with the adhesive bearingsurface of the first outer layer; and

curing the laminate so formed.

The light curable adhesive may be delivered to a surface of the firstouter layer utilising any suitable technique. A syringe technique may beused.

The light curable adhesive may be of any suitable type. The lightcurable adhesive may be a visible light curable adhesive. The visiblelight curable adhesive may be selected from the group consisting ofDymax 469 and 492, Electro-Lite Corporation 4M12, Loctite 3321, MasterBond UV15-7 and 15X-2, and Lite-Fast Adhesive A-109 from Micro-LiteTechnology.

The adhesive may contact the surface generally centrally thereof, toprovide a generally even spread of adhesive when contact with the innerlayer is made. The adhesive coating step may continue for a periodsufficient to permit the adhesive to spread over a substantialproportion of the surface. A period of 60 to 180 seconds is preferred.

Where the first outer layer is a front lens wafer, the contacting stepmay include orienting the inner layer relative to any characteristicfeature or function of the front lens wafer. For example, the axis ofpolarisation should be orthogonal to the ledge on a flat top bifocalfront.

In a preferred aspect, the curing step may include

subjecting the laminate to an initial cure whilst maintaining thecomponents in contact under pressure for a time sufficient to achieveacceptable tack, and

subjecting the partially cured laminate to a final cure through thefront and back surface thereof.

Preferably the initial and/or final cure is a visible light or UV cure.

In a further preferred aspect, the method may further include

providing a second outer layer formed from an optical polymericmaterial;

coating at least a portion of a surface of the second outer layer withthe light curable adhesive;

contacting a surface of the inner layer with the adhesive bearing secondouter layer; and

curing the laminate so formed.

Where the second outer layer is a back lens wafer, the contacting stepmay include orienting the cylinder on the back lens wafer according tothe optical prescription requested. A surface of one or more of thelayers may be subjected to a surface treatment. Accordingly, in apreferred aspect of the present invention, the method may furtherinclude in a preliminary step a surface or part thereof of one or moreof the layers is subjected to a surface treatment to improve bondabilityand/or compatibility.

The surfaces or parts of the surfaces of one or more of the layersmaking up the laminate may be modified to improve bondability and/orcompatibility. The treatment may include physical and/or chemicalmodification of the surface of the polymer. These surface treatments maybe selected from one or more of the group consisting of dischargetreatment including plasma discharge, corona discharge, glow discharge,ionising radiation, UV radiation, flame treatment and/or excimer lasertreatment. This treatment may be carried out in the presence of asuitable atmosphere, for example, oxygen, nitrogen, carbon dioxide,helium, argon and/or mixtures of these gases.

The treatment conditions and the time of treatment may be selected tosuit the particular polymer type and other factors. The properties ofthe polymer surface may be altered by chemical means such as surfacechemical grafting or by some other chemical treatment. A plasmadischarge or corona discharge treatment is preferred. A low pressure airplasma treatment is particularly preferred.

The curing step may be a one step or two step process. The curing mayoccur after the inner layer is contacted with both the first outer layerand second outer layer. Alternatively the inner layer may be contactedwith one outer layer and cured, after which the other outer layer isplaced in contact with the inner layer and cured.

Accordingly in a still further preferred aspect, there is provided amethod for preparing a laminate optical article including

providing

a first outer layer formed from an optical polymeric material;

a second outer layer formed from an optical polymeric material;

an inner layer with the adhesive bearing second outer layer; and

a light curable adhesive;

coating at least a portion of a surface of the inner layer and one ofthe first or second outer layers with light curable adhesive;

contacting the adhesive bearing surfaces;

coating at least a portion of the other surface of the inner layer andthe other of the first or second outer layers;

contacting the other adhesive bearing surfaces to form a laminate;

subjecting the laminate to an initial cure whilst maintaining thecomponents in contact under pressure for a time sufficient to achieveacceptable tasks; and

subjecting the partially cured laminate to a final cure through thefront and back surface thereof.

Desirably, the laminate may be reversed to complete the cure or the UVlight, preferably visible or UV light may be directed from both sides ofthe laminate.

The present invention will now be more fully described with reference tothe accompanying examples. It should be understood, however, that thedescription following is illustrative only and should not be taken inany way as a restriction on the generality of the invention describedabove.

EXAMPLES

Following is the description of the front and back lens wafer and innerlayer components used in the following examples.

Front Polymeric Lens Wafer:

6.00 D interface curve

Diallyl glycol carbonate material

Hardcoat only

Back Polymeric Lens Wafer:

6.00 D interface curve

Diallyl glycol carbonate material

No coat

Inner Polarising Film Layer:

Preformed to 6.00 Base Curve

The lenses were subjected to the following tests:

Test Sample Description

All durability tests were performed on edged and surfaced plano samples,so as to ensure the most vulnerable test sample configuration.

The laminated 6.00 D base semi-finished polarising lenses were edged andsurfaced as follows:

Lenses were diameter reduced (edged) from initial diameter 74 mm tofinal diameter 68 mm

Lenses were surfaced to 6.00 D base planos with centre thickness of 2.5mm.

Test Method Description

A sequence of steps was followed to assess the durability of laminatedoptical articles, by visual examination of any signs of delamination.Lenses were assessed after:

Lamination completed

Diameter reduction by edging

Thickness reduction by surfacing

3 Hour Boil Test

72 hours Atlas Weatherometer Humidity test

3 Hour Boil Test

Lenses were immersed in boiling water and examined visually fordelaminations at 15 minute, 30 minute, 1 hours, 2 hours and 3 hoursintervals. Additional % transmission and L*, a*, B* were measured at theintervals to illustrate overall durability of the polarising films.

Atlas Weatherometer Humidity Test

Lenses are stored in Atlas Weatherometer chamber for 72 hours, withinspection for delaminations every 24 hours. The conditions inside theWeatherometer are 65° C. with 99% relative humidity. There is a twohours cycle time for increasing and decreasing temperature between60-70° C.

Again, % transmission and colour coordinates were regularly checked asan indication of the polarising films' durability.

Example 1

A UV curable adhesive was applied to a front polymeric lens wafer. Apolyvinyl alcohol-type polarising film was then placed in contact withthe wafer. The film is shaped to the curve of the laminate interface,typically 6D. The film was moved so that its edges align with thelaminate element and properly oriented relative to any characteristicfeature or function of the front lens wafer. For example, the axis ofpolarisation should be orthogonal to the ledge on a flat top bifocalfront. Once the foil was correctly oriented with respect to the frontwafer, the cylinder on the back wafer was oriented according to theoptical prescription required. Next, UV curable adhesive was placed on aback wafer placing it over the wafer element on which the polarisingfilm has been placed. The axis was aligned and the adhesive UV cured asa standard lamination process. Once complete, the element may bereversed and given a supplementary UV treatment through the side thatwas shaded by the polarising film during the normal laminationoperation. The lens was then edged and fitted. A lens of high qualityand structural integrity was produced. No signs of delamination wereobserved.

Example 2

Lamination of Semi-Finished Polarising Lenses

A similar process was undertaken to that described in Example 1 above,with the following modifications.

Lamination Parts

The lamination process for semi-finished lenses consists of combining afront lens wafer with an inner polarising film layer and a semi-finishedback component with adhesive in each of four interfaces.

Example 3

The procedure of Example 1 was repeated to the point where thepolarising film has been adhered to the front lens wafer. (Note: Somegentle pressure on the polarising film may be needed to get goodconformity between it and the interface curve of the front laminateelement). The front lens wafer bearing the polarising film or foil maythen be packaged and shipped to be used as a standard laminate element.A finished polarising lens may then be produced by applying a back lenselement at a later time.

Example 4

The front lens wafer to which the polarising foil has been glued, as inExample 3, was subsequently coated with a peelable interface coating toprotect the polarising film from physical damage. When peeled, justprior to lamination, a pristine surface is revealed, even if theexternal surface of the polarising film had been dirty at the time theinterface coating was applied.

Example 5

Surface Treatment

The process of Example 1 was repeated except that the polarising filmwas subjected to a plasma treatment. The plasma treatment of polarisingfilms was carried out in a Plasmod plasma system, manufactured by MarchInstruments (USA)

Following is a description of conditions used in plasma treatment.

Gas type: Air

Vacuum: 1 Torr

Power: 30-50 W

Duration: 10-60 sec

Low Pressure Plasma Treatment of Polarising Films—X-Ray Photo ElectronSpectroscopy (XPS) Analysis

The polarising film layers were formed of PVA based material impregnatedwith a chromophore. The films were exposed to low pressure air plasmafor 60 seconds, and the surface of the films were analysed by XPS.General XPS survey scan indicates the types of elements present in thesurface.

The following tables summarise the surface atomic concentrationsobtained from general survey scans.

TABLE 1 Surface Atomic Concentrations Before Plasma Element Conc (%)After Plasma Conc (%) Carbon 70.5 62.5 Oxygen 29.5 36.4 Nitrogen 0 1.1

From the results it is obvious that oxygen concentration, as expected,has significantly increased after plasma treatment. Also, a small amountof nitrogen has been grafted onto the surface after plasma treatment.

Effect of Low Pressure Plasma Treatment on Durability of LaminatedLenses

The polarising films were exposed to low pressure air plasma for 60seconds. The treated films were laminated into a semi-finished productfollowing standard laminating technique. The durability of the lens wascompared to lenses, where films were laminated in untreated form. Avisual examination for delaminations was performed after lamination,edging, surface, 3 Hour Boil test and 72 hours Humidity test.

Lenses laminated using plasma treated or untreated films during edgingand surfacing could not be distinguished. There were no delaminationdefects determined in any of the lens samples studied.

However, during 3 Hour Boil test and 72 Hour Humidity test, differencesbetween lenses became obvious.

Following table 2 summarises the results.

TABLE 2 3 Hour Boil Test (Polarising Film) Time Initial 18 Min 30 Min 1Hour 2 Hours 3 Hours POLARISING FILM - UNTREATED Delam. No delam. Delam.up to 5 mm Delam. increasing Delam. not Film further Film further fromedge up to 10 mm from increas. Film: dissolving dissolving edgedissolving % T 17 16 16 17 18 20 L* 48 47 47 49 50 52 a* −2.7 −2.7 −2.5−2.3 −1.7  −0.40 b* +0.9 +0.9  −0.08  −0.05  +0.50  −1.20 POLARISINGFILM - PLASMA TREATED Delam. No No Delam. No Delam. No Delam. No Delam -No Delam - Delam. Film slightly Film retracted retracting up to 1 mm % T16 16 17 17 18 22 L* 48 48 48 49 50 54 a* −2.6 −2.6 −2.8 −2.6  −1.30−0.2 b* +0.8 +0.5  +0.02 +0.2 −0.3 −2.2

From results in table 2, it is obvious that lenses which were laminatedusing untreated polarising film started to delaminate after 15 minutesin boiling water. Most of the delaminations occurred within the firsthour of boiling, which was then followed by total destruction of thepolarising film within the delaminated areas.

Lenses which were laminated using plasma treated film did not delaminateduring the entire 3 Hours Boiling test duration. Only slight filmretraction is obvious after 2 hours of boiling.

The durability of lenses was studied in 72 Hours Humidity test. Lenseswere checked visually for delaminations at 24 hour intervals. Table 3summarises the results.

TABLE 3 Atlas Weatherometer Humidity Test Plasma Film Type TreatmentInitial 24 Hours 48 Hours 72 Hours Polarising No No Delam up to DelamFilm film de- 3 mm around increasing dissolving in lam edges up to 5 mmdelam area Polarising Yes No No delam No delam No delam film de- lam

Again, the effect of plasma treatment is clearly obvious. Lenseslaminated with treated film did not exhibit any delaminations, whilstlenses which were laminated using untreated film delaminated within 24hours.

Example 6 Comparative Polarising Lenses Durability Assessment

Laminated polarising lenses according to the present invention werecompared to two prior art products, Talex (Japan) and Younger Optics(USA). The performance of the lenses was assessed using 72 hoursHumidity test.

Visual assessment of delaminations were performed at 24 hour intervals,and colour coordinates were measured to examine overall durability ofpolarising films.

The following table summarises the overall rating given to thedurability performance of compared lenses.

Lens Type Rating Laminated Optical lens 1 Talex Grey 2 Talex Brown 2Younger Optics 10 1 = Best, 10 = worst

Talex product and laminated optical lenses performed well in 72 hourHumidity test. Lenses manufactured by Talex did not show any signs ofdelaminations, however the polarising film retracted up to 2 mm from theedge of the lenses, after 72 hours exposure. The laminated lensesaccording to the present invention did not show any signs ofdelaminations and no film retractions from the edge. Lenses manufacturedby Younger Optics started delaminating after 24 hours exposure. At theend of 72 hours exposure, the lenses were almost fully delaminated withsevere substrate cracking in the front portion of the lenses.

The following table 5 shows the initial and final colour coordinates oftested lenses, in an attempt to illustrate the stability of thepolarising films.

TABLE 5 Effect of 72 Hour Humidity Test on Colour Stability of the FilmInitial Final Lens Type % T L* a* b* % T L* a* b* Laminated Optical 1749 −2 −2 17 49 −1 −2 Lens Talex Grey 10 37 +1 −3 11 39 +5 −1 Talex Brown29 61 +3 +19  33 64 +5 +20  Younger Optics 39 68 −4 +7 67 86 −2 +1

The laminated optical lens according to the present invention exhibitsthe best stability, following by films used in Talex product. However,film used in Younger Optics Products displayed a very poor temperaturestability, graining up to 30% in transmission and completely losingcolour.

Example 7

a) UV Curable Adhesive (Comparative)

The process of Example 5 was repeated except that the front lens waferwas formed either from an inherently UV absorbing polymeric material orfrom a polymeric material modified to exhibit UV cutoff at a preselectedwavelength (e.g. 320 nm to 380 nm).

The results are provided in Table 6 below.

TABLE 6 Effect of UV absorbing substrates on cure of Dymax 492 %Conversion Cure Time Polarising (min) UV320 UV350 UV370 UV380 film 0.210 2 0 0 0 0.4 38 12 0.2 0 0 0.6 59 26 0.4 0 0 0.8 74 39 0.7 0 0 1.0 8349 1 0 0 2.0 92 79 7 0.2 3 5.0 94 90 35 3 35 10.0 97 92 62 12 69 90%conversion has to be achieved - otherwise cure inadequate

D492—conventional UV cured adhesive

Conclusion

Dymax 492 cannot cure UV absorbing substrates

b) Visible light curable adhesive

The process of Example 7a was repeated except that a range of visiblelight curable adhesives were used.

The results are provided in Table 7 below.

TABLE 7 CR496 - Effect of UV absorbing substrates Cure Time UV380/Photochromic (min) UV 320 UV 380 Polarising Photochromic PolycarbonatePolarising Polarising 0.2 11  6  3  5  5  3  4 0.4 37 29 13 24 22 13 160.6 55 47 26 41 39 26 33 0.8 68 60 38 53 51 38 42 1.0 76 70 46 62 59 4651 2.0 86 84 71 82 79 71 80 5.0 90 88 85 89 87 85 87 10.0 94 90 89 91 9089 90 CR496 - Proprietary SOLA visible adhesive X279381 - commercialvisible light adhesive UV 380/polarising - means two layersPhotochromic/polarising - means two layers Polycarbonate is inherentlyUV absorbing polymer 90% conversion achieved in all cases - cureadequate

TABLE 8 X-270-38-1 Effect of UV absorbing substrates % Conversion CureTime UV 380/ Photochromic/ (min) UV 320 UV380 Polarising FilmPhotochromic Polarising Polarising 0.2  8  8  1  7  1  5 0.4 34 35  6 28 6 22 0.6 51 54 15 46 14 38 0.8 64 66 26 57 23 48 1.0 73 75 35 65 32 592.0 88 86 61 83 57 78 5.0 92 90 83 89 79 85 10.0 97 94 90 91 87 90 DymaxX-279-38-1 - Commercially available visible adhesive Approximately 90%conversion achieved in all cases - cure adequate

Example 8 Laminate Lens Element Bearing Protective Coating

Laminate lens elements comprising a front polymeric lens wafer and aninner polarising film layer were coated with a protective coatingcomprising a vinyl chloride/vinyl acetate copolymer dissolved in acetoneand subsequently dried.

After three weeks there was no visible effect of the polarising filmlayer on the protective coating. There was no discolouration of thefilms and no evidence of dye transfer from the polarising film into theprotective coating.

Effect of Exposure of Laminated Semi-Finished Lenses to Acetone

The laminated lens elements comprising a front polymeric lens wafer andan inner polarising film layer were soaked in acetone for 48 hours.

As acetone is a major component of a typical protective interfacecoating, the soaking process is an extreme test of the ability of thelaminated lens element to withstand the protective coating process. Forexample, in a typical process the interface coating step continues forless than approximately one minute prior to drying.

After 48 hours, there was no obvious loss of colour in the polarisingfilm and no obvious loss of polarisation. Further the acetone had notpicked up any colour from the films.

Slight penetration of acetone along the glue layer was apparent but nodelamination was apparent.

Example 9 Lamination of Photochromic Lenses

A similar process was undertaken to that described in Example 1 above,with the following modifications.

The lamination process consists of laminating a front lens wafer with aninner photochromic layer and a back lens wafer with adhesive in each offour interfaces.

The inner photochromic layer comprises a cast flexible film,incorporating photochromic dyes. This film was shaped to match theinterface curves on the front and back lens wafers.

The photochromic film is a polyoxyalkylene glycol dimethacrylate withurethane methacrylate including a mixture of three photochromic dyes.The photochromic dyes are selected from any of those descried above. Atypical mixture comprises a Reversacol Corn Yellow, Reversacol Berry Redand Reversacol Sea Green.

The laboratory lamination was performed using a standard laminationtechniques. CR496 was used as the visible light curable adhesive.

The final cure of the adhesive was achieved by exposing the front andback surface of the laminated lens for four minutes (back surface).

A lens of high quality and structural integrity, exhibiting photochromiceffects, was produced.

Example 10 Lamination of Photochromic/Polarising Lenses Example 10A

A similar process was undertaken to that described in Example 1 above,with the following modifications.

The lamination process comprised laminating a front lens wafer with aninner shaped polarising film layer in the manner described in Example 1above. The inner shaped polarising film layer was formed from a PVAmaterial impregnated from a chromophore.

An inner photochromic layer as described in Example 9 above waslaminated to the polarising film coated front lens wafer and a back lenswafer with adhesive in each of the four interfaces.

The laboratory lamination was performed using a standard laminationtechniques. CR496 was used as the visible light curable adhesive.

The final cure of the adhesive was achieved by exposing the front andback surface of the laminated lens for four minutes (back surface).

Example 10B

The process of Example 10A was repeated but the order of shapedpolarising film layer and inner photochromic layer reversed.

In both examples, a lens of high optical quality and structuralintegrity, exhibiting a combination of photochromic and polarisationeffects, was produced.

Finally, it is to be understood that various other modifications and/oralterations may be made without departing from the spirit of the presentinvention as outlined herein.

What is claimed is:
 1. A laminate optical article including a firstouter layer, a second layer and at least one inner layer positionedbetween the first and second out layers, at least one inner layerincluding a photochromic material therein wherein a surface or partthereof of one or more of the layers is subjected to a surface treatmentto improve bondability and/or compatibility, the surface treatment beingselected from one or more of the group consisting of plasma discharge,corona discharge, glow discharge, ionizing radiation, UV radiation,flame treatment, and laser treatment.
 2. A laminate optical articleaccording to claim 1, wherein the first outer layer forms a front orback wafer of an optical lens and includes an optical surface and aninterface or mating surface.
 3. A laminate optical article according toclaim 2, wherein the first outer layer is formed from a glass or opticalpolymeric material.
 4. A laminate optical article according to claim 3,wherein the first outer layer is formed from a polycarbonate material.5. A laminate optical article according to claim 2, wherein the secondouter layer forms a complementary back or front wafer of a laminateoptical.
 6. A laminate optical article according to claim 5, wherein thesecond outer layer is formed from a glass or optical polymeric material.7. A laminate optical article according to claim 6, wherein the secondouter layer is formed from a polycarbonate material.
 8. A laminateoptical article according to claim 2, wherein an optical surface thereofincludes an anti-reflective (AR) coating and/or abrasion resistantcoating thereon.
 9. A laminate optical article according to claim 1,wherein the second outer layer forms a protective coating for the innerlayer.
 10. A laminate optical article according to claim 9, wherein theprotective coating includes one or more of the group consisting of anabrasion resistant component, a water resistant component and anantistatic component.
 11. A laminate optical article according to claim1, wherein the inner layer includes a polymeric film or foil having thephotochromic material therein.
 12. A laminate optical article accordingto claim 11, wherein the inner layer has a shape complementary to asurface of the first and/or second outer layers.
 13. A laminate opticalarticle according to claim 12, wherein the inner layer has a curvaturewhich substantially corresponds to the curvature of the inner surface ofthe first and/or second outer layer.
 14. A laminate optical articleaccording to claim 11, wherein the polymeric film or foil includes anactive light polarising film.
 15. A laminate optical article accordingto claim 1, wherein the inner layer includes a photochromic dye(s)selected from one or more of the group consisting of anthraquinones,phthalocyanines, spiro-oxazines, chromenes, pyrans includingspiro-pyrans, and fulgides.
 16. A laminate optical article according toclaim 1, including a plurality of inner layers each providing at leastone of (i) polarization property, (ii) photochromicity property, or(iii) color property to the laminate optical article.
 17. A laminateoptical article according to claim 16, including an inner polarisingfilm layer and an inner photochromic layer.
 18. A laminate opticalarticle according to claim 1, wherein the inner layer is subjected to aplasma or corona discharge treatment.
 19. A laminate optical articleincluding a first front lens wafer formed from an optical polymericmaterial; a second complementary back lens wafer formed from an opticalpolymeric material; and an inner layer positioned between said front andback lens wafer and having a shape complementary to a surface of thefront and/or back wafer, the inner layer including a photochromicmaterial therein wherein a surface or part thereof of at least one ofthe first front lens wafer, second complementary back lens wafer, orinner layer is subjected to a surface treatment to improve bondabilityand/or compatibility, the surface treatment being selected from one ormore of the group consisting of plasma discharge, corona discharge, glowdischarge, ionizing radiation, UV radiation, flame treatment, and lasertreatment.
 20. A series of laminate optical articles, each member of theseries including a back lens wafer formed from an optical polymericmaterial; an outer layer forming a protective coating; and an innerlayer positioned between said back lens wafer and outer protectivelayer, the inner layer including a photochromic material therein andbeing shaped to have a curvature substantially corresponding to theinterface surface of the back lens wafer wherein a surface or partthereof of at least one of the back lens wafer, outer layer, or innerlayer is subjected to a surface treatment to improve bondability and/orcompatibility, the surface treatment being selected from one or more ofthe group consisting of plasma discharge, corona discharge, glowdischarge, ionizing radiation, UV radiation, flame treatment, and lasertreatment.
 21. A laminate optical article series according to claim 20,wherein the protective coating is formed from a vinyl chloride/vinylacetate copolymer.
 22. A laminate optical article including a front lenswafer formed from an optical polymeric material; an outer layer forminga protective coating; and an inner layer positioned between said frontlens wafer and outer protective layer, the inner layer including aphotochromic material therein and being shaped to have a curvaturesubstantially corresponding to the interface surface of the front lenswafer wherein a surface or part thereof of at least one of the frontlens wafer, outer layer, or inner layer is subjected to a surfacetreatment to improve bondability and/or compatibility, the surfacetreatment being selected from one or more of the group consisting ofplasma discharge, corona discharge, glow discharge, ionizing radiation,UV radiation, flame treatment, and laser treatment.
 23. A laminateoptical article according to claim 22, wherein the protective coating isformed from a vinyl chloride/vinyl acetate copolymer.
 24. A laminateoptical article according to claim 22, further including a complementaryback lens wafer formed from an optical polymeric material.
 25. A methodfor preparing a laminate optical article including: providing a firstouter layer formed from an optical polymeric material; an inner layerformed from a polymeric film wherein a surface or part thereof of theinner layer is subjected to a surface treatment to improve bondabilityand/or compatibility, the surface treatment being selected from one ormore of the group consisting of plasma discharge, corona discharge, glowdischarge, ionizing radiation, UV radiation, flame treatment, and lasertreatment; and a light curable adhesive; coating at least a portion of asurface of the first outer layer with the light curable adhesive;contacting a surface of the inner layer with the adhesive bearingsurface of the first outer layer; and curing the laminate so formed,wherein the inner layer includes a photochromic material therein.
 26. Amethod according to claim 25, wherein the light curable adhesive isdelivered to a surface of the first outer layer generally centrallythereof, utilising a syringe technique, to provide a generally evenspread of adhesive when contact with the inner layer is made.
 27. Amethod according to claim 26, wherein the adhesive coating stepcontinues for a period sufficient to permit the adhesive to spread overa substantial proportion of the surface.
 28. A method according to claim25, wherein the curing step includes: subjecting the laminate to aninitial cure whilst maintaining the components in contact under pressurefor a time sufficient to achieve acceptable tack; and subjecting thepartially cured laminate to a final cure through the front and backsurface thereof.
 29. A method according to claim 28, wherein the initialand/or final cure is a visible light or UV cure.
 30. A method accordingto claim 25, further including providing a second outer layer formedfrom an optical polymeric material; coating at least a portion of asurface of the second outer layer with the light curable adhesive;contacting a surface of the inner layer with the adhesive bearing secondouter layer; and curing the laminate so formed.
 31. A method accordingto claim 25, wherein the inner layer is subjected to a plasma or coronadischarge treatment.
 32. A method for preparing a laminate opticalarticle including: providing a first outer layer formed from an opticalpolymeric material, a second outer layer formed from an opticalpolymeric material, an inner layer, and a light curable adhesive;coating at least a portion of a surface of the inner layer and one ofthe first or second outer layers with light curable adhesive; contactingthe adhesive bearing surfaces; coating at least a portion of the othersurface of the inner layer of the other of the first or second outerlayers with light curable adhesive; contacting the other adhesivebearing surfaces to form a laminate subjecting the laminate to aninitial cure whilst maintaining the components in contact under pressurefor a time sufficient to achieve acceptable tack; and subjecting thepartially cured laminate to a final cure through the front and backsurface thereof, wherein the inner layer comprises a polymeric film orfoil that includes a photochromic material therein.
 33. A laminateoptical article including a first outer layer, a second outer layer, andat least one inner layer positioned between the first and second outerlayers, wherein the first outer layer, the second outer layer and atleast one inner layer have a light curable adhesive therebetween, andwherein the at least one inner layer provides at least one of (i)polarization property, (ii) photochromicity property, or (iii) colorproperty to the laminate optical article and the inner layer comprises apolymeric film or foil.
 34. A laminate optical article according toclaim 33, wherein the first outer layer forms a front or back wafer ofan optical lens and includes an optical surface and an interface ormating surface.
 35. A laminate optical article according to claim 34,wherein the first outer layer is formed from a glass or opticalpolymeric material.
 36. A laminate optical article according to claim35, wherein the first outer layer is formed from a polycarbonatematerial.
 37. A laminate optical article according to claim 34, whereinthe second outer layer forms a complementary back or front wafer of alaminate optical.
 38. A laminate optical article according to claim 37,wherein the second outer layer is formed from a glass or opticalpolymeric material.
 39. A laminate optical article according to claim38, wherein the second outer layer is formed from a polycarbonatematerial.
 40. A laminate optical article according to claim 34 whereinan optical surface thereof includes an anti-reflective (AR) coatingand/or abrasion resistant coating thereon.
 41. A laminate opticalarticle according to claim 33, wherein the second outer layer forms aprotective coating for the inner layer.
 42. A laminate optical articleaccording to claim 41, wherein the protective coating includes one ormore of the group consisting of an abrasion resistant component, a waterresistant component and an antistatic component.
 43. A laminate opticalarticle according to claim 33, wherein the inner layer has a shapecomplementary to a surface of the first and/or second outer layers. 44.A laminate optical article according to claim 43, wherein the innerlayer has a curvature which substantially corresponds to the curvatureof the inner surface of the first and/or second outer layer.
 45. Alaminate optical article according to claim 33, wherein the polymericfilm or foil includes an active light polarising film.
 46. A laminateoptical article according to claim 33, wherein the polymeric film orfoil has incorporated therein an optically active component selectedfrom the group consisting of one or more of the group consisting oflight polarising materials, ultra-violet inhibitors, photochromicmaterials, electrochromic materials and other pigments or dyes.
 47. Alaminate optical article according to claim 46, wherein the inner layerincludes a photochromic dye(s) selected from one or more of the groupconsisting of anthraquinones, phthalocyanines, spiro-oxazines,chromenes, pyrans including spiro-pyrans, and fulgides.
 48. A laminateoptical article according to claim 33, including a plurality of innerlayers each providing one or more desirable optical properties to thelaminate optical article.
 49. A laminate optical article according toclaim 48, including an inner polarising film layer and an innerphotochromic layer.
 50. A laminate optical article according to claim33, wherein a surface or part thereof of one or more of the layers issubjected to a surface treatment to improve bondability and/orcompatibility.
 51. A laminate optical article according to claim 50,wherein the surface treatment is selected from one or more of the groupconsisting of plasma discharge, corona discharge, glow discharge,ionising radiation, UV radiation, flame treatment and laser treatment.52. A laminate optical article according to claim 51, wherein the innerlayer is subjected to a plasma or corona discharge treatment.
 53. Alaminate optical article including a first front lens wafer formed froman optical polymeric material; a second complementary back lens waferformed from an optical polymeric material; and an inner layer positionedbetween said front and back lens wafer and having a shape complementaryto a surface of the front and/or back wafer, wherein the inner layercomprises a polymeric film or foil that provides at least one of (i)polarization property, (ii) photochromicity property, or (iii) colorproperty to the laminate optical article, and wherein the back wafer andinner layer have a light curable adhesive therebetween.
 54. A series oflaminate optical articles, each member of the series including a backlens wafer formed from an optical polymeric material; an outer layerforming a protective coating; and an inner layer positioned between saidback lens wafer and outer protective layer, wherein the inner layercomprises a polymeric film or foil that provides at least one of (i)polarization property, (ii) photochromicity property, or (iii) colorproperty to each member and the inner layer is shaped to have acurvature substantially corresponding to the interface surface of theback lens wafer, wherein the layers have a light curable adhesivetherebetween.
 55. A laminate optical article series according to claim54, wherein the protective coating is formed from a vinyl chloride/vinylacetate copolymer.
 56. A series of laminate optical articles, eachmember of the series including a back lens wafer formed from an opticalpolymeric material; an outer layer forming a protective coating; and aninner layer positioned between said back lens wafer and outer protectivelayer, wherein the inner layer provides at least one of (i) polarizationproperty, (ii) photochromicity property, or (iii) color property to eachmember and the inner layer is shaped to have a curvature substantiallycorresponding to the interface surface of the back lens wafer, whereinthe layers have a light curable adhesive therebetween wherein successivemembers of the series have suitable sphere and cylinder power to enablea member of the series to be used in combination with any design andpower of front lens wafer to produce a finished lens within the normaltolerances for such lenses.
 57. A laminate optical article including afront lens wafer formed from an optical polymeric material; an outerlayer forming a protective coating; and an inner layer positionedbetween said back lens wafer and outer protective layer, wherein theinner layer comprises a polymeric film or foil that provides at leastone of (i) polarization property, (ii) photochromicity property, or(iii) color property to the laminate optical article and the inner layeris shaped to have a curvature substantially corresponding to theinterface surface of the front lens wafer, wherein the layers have alight curable adhesive therebetween.
 58. A laminate optical articleaccording to claim 57, wherein the protective coating is formed from avinyl chloride/vinyl acetate copolymer.
 59. A laminate optical articleaccording to claim 57, that further includes a back lens wafer.
 60. Amethod for preparing a laminate optical article including: providing afirst outer layer formed from an optical polymeric material, an innerlayer formed from a polymeric film that provides at least one of (i)polarization property, (ii) photochromicity property, or (iii) colorproperty to the final product wherein a surface or part thereof of theinner layer is subjected to a surface treatment to improve bondabilityand/or compatibility, the surface treatment being selected from one ormore of the group consisting of plasma discharge, corona discharge, glowdischarge, ionizing radiation, UV radiation, flame treatment, and lasertreatment, and a light curable adhesive; coating at least a portion of asurface of the first outer layer with the light curable adhesive;contacting a surface of the inner layer with the adhesive bearingsurface of the first outer layer; and curing the laminate so formed. 61.A method according to claim 60, wherein the light curable adhesive isdelivered to a surface of the first outer layer generally centrallythereof, utilising a syringe technique, to provide a generally evenspread of adhesive when contact with the inner layer is made.
 62. Amethod according to claim 61, wherein the adhesive coating stepcontinues for a period sufficient to permit the adhesive to spread overa substantial proportion of the surface.
 63. A method according to claim60, wherein the curing step includes: subjecting the laminate to aninitial cure whilst maintaining the components in contact under pressurefor a time sufficient to achieve acceptable tack; and subjecting thepartially cured laminate to a final cure through the front and backsurface thereof.
 64. A method according to claim 63, wherein the initialand/or final cure is a visible light or UV cure.
 65. A method accordingto claim 60, further including providing a second outer layer formedfrom an optical polymeric material; coating at least a portion of asurface of the second outer layer with the light curable adhesive;contacting a surface of the inner layer with the adhesive bearing secondouter layer; and curing the laminate so formed.
 66. A method forpreparing a laminate optical article including: providing a first outerlayer formed from an optical polymeric material, a second outer layerformed from an optical polymeric material, an inner layer, and a lightcurable adhesive; coating at least a portion of a surface of the innerlayer and one of the first or second outer layers with light curableadhesive; contacting the adhesive bearing surfaces; coating at least aportion of the other surface of the inner layer and the other of thefirst or second outer layers with light curable adhesive; contacting theother adhesive bearing surfaces to form a laminate subjecting thelaminate to an initial cure whilst maintaining the components in contactunder pressure for a time sufficient to achieve acceptable tack; andsubjecting the partially cured laminate to a final cure through thefront and back surface thereof, wherein in a preliminary step, a surfaceor part thereof of one or more of the layers is subjected to a surfacetreatment to improve bondability and/or compatibility, the surfacetreatment being either a plasma discharge treatment or a coronadischarge treatment.
 67. A method for preparing a laminate opticalarticle including: providing a first outer layer formed from an opticalpolymeric material; an inner layer formed from a polymeric film whereina surface or part thereof of the inner layer is subjected to a surfacetreatment to improve bondability and/or compatibility, the surfacetreatment being selected from one or more of the group consisting ofplasma discharge, corona discharge, glow discharge, ionizing radiation,UV radiation, flame treatment, and laser treatment; and a light curableadhesive; coating at least a portion of a surface of the first outerlayer with the light curable adhesive; contacting a surface of the innerlayer with the adhesive bearing surface of the first outer layer; andcuring the laminate so formed, wherein the inner layer includes a lightpolarizing material therein.
 68. A method according to claim 67, whereinthe light curable adhesive is delivered to a surface of the first outerlayer generally centrally thereof, utilizing a syringe technique, toprovide a generally even spread of adhesive when contact with the innerlayer is made.
 69. A method according to claim 68, wherein the adhesivecoating step continues for a period sufficient to permit the adhesive tospread over a substantial proportion of the surface.
 70. A methodaccording to claim 67 wherein the curing step includes: subjecting thelaminate to an initial cure while maintaining the components in contactunder pressure for a time sufficient to achieve acceptable tack; andsubjecting the partially cured laminate to a final cure through thefront and back surface thereof.
 71. A method according to claim 70wherein the initial and/or final cure is a visible light or UV cure. 72.A method according to claim 67, further including providing a secondouter layer formed from an optical polymeric material; coating at leasta portion of a surface of the second outer layer with the light curableadhesive; contacting a surface of the inner layer with the adhesivebearing second outer layer; and curing the laminate so formed.
 73. Amethod according to claim 67 wherein the inner layer is subjected to aplasma or corona discharge treatment.